2005 Assembly & Operation Manual Models: 810 & 8611

Transcription

1 2005 Assembly & Operation Manual Models: 810 & 8611 B /4/05

2 INTRODUCTIONS/TABLE OF CONTENTS Congratulations on purchasing the most advanced snowplow available! The Blizzard Power Plow snowplow is clearing new trails for innovative design, rugged durability, quality craftsmanship and superior performance. Our exclusive products are manufactured and tested in Michigan s Upper Peninsula, the snow capital of the Midwest. With an annual snowfall averaging over 250" we couldn t imagine building snow removal products anywhere else! TABLE OF CONTENTS Safety... 3 Operation... 4 Unpacking & Inspection... 5 Technical Specifications... 6 Torque Specifications... 7 Moldboard & A-Frame Assembly... 8 Electrical-Plow Side Electrical-Vehicle Side Power Hitch Instructions Testing your Plow Maintenance Troubleshooting Moldboard & Wing Parts A-Frame & Pivot Beam Parts Power Unit Parts Lights & Controls Parts Accessories & Kits Warranty

3 SAFETY WARNING CAUTION Prior to operating your Power Plow snowplow, review the WARNING! label at the passenger s side rear of the moldboard (shown below). NOTE: Read and understand all warnings indicated in this manual prior to operating the snowplow. Warnings and cautions in the manual are indicated by the icons shown at left. NOTE: If at any time the safety labels become illegible, promptly replace them. 3

4 OPERATION Your Blizzard Power Plow snowplow is the most advanced and versatile snowplow on the market. The easy-to-use controls allow you to automatically adjust the plow blade and wings into an infinite number of plowing positions. Review the illustrations below to determine the best position for your plowing needs. A. B. C. A. Compact Position (8' or 8'-6" Blade Width) Primary position when transporting the snowplow For use in heavy snow conditions with poor visibility, initial clearing and tight quarters Ideal application: Residential driveways, small roads B. WidePass Position (10' or 11'-3" Blade Width) Primary position for clearing large surfaces For use in light snow conditions with good visibility, final clearing and cleanup Ideal application: Large parking lots, widening roadways C. BucketBlade Position ('-3" or '-10" Blade Width) Primary position for transporting snow For use in initial clearing with decent visibility, transporting large volumes of snow, final clean-up Ideal application: Roadway intersections D. WidePass Position Angled with Wing Forward Primary position for accelerated angled plowing For use in directional plowing, cornering, diverting snow away from objects or buildings Ideal application: Plowing adjacent to buildings, driveway /road intersections D. ***** IMPORTANT ***** To prevent premature failure of the power contactor (solenoid), initiate the plow function and return the rocker switch and/or joystick to its neutral or center position. DO NOT hold a rocker switch and/or joystick in any position that allows the pump to continuously run after the main blade or wing has reached its maximum degree of movement. This will reduce the life of the solenoid. 4

5 UNPACKING & INSPECTION Your Blizzard Power Plow snowplow has been packaged to withstand transit and weather related damage. Fully inspect all components upon receipt of your plow. In the event of shipping damage or missing parts, immediately contact our Customer Service Department at Begin unpacking and inspection in the following order: 1. Remove the shipping document from the end panel of the pallet wrap. Retain all documentation for your records. 2. All wood framing and polyethylene material should be removed from the pallet for easy access to the snowplow. 3. Due to the odd shaped components and size of several assembly parts, various cable ties and corrugated material are used for scratch resistance and package orientation. Please remove these items prior to assembly. 4. Place the main blade assembly on a flat, level surface. Once you have inspected all parts and removed all packaging materials, your snowplow is ready to be fully assembled. Retain this information for your records. DATE OF PURCHASE: DEALER/DISTRIBUTOR: DEALER PHONE NUMBER: Pallet Wrap End Panel The tear-resistant, woven polyethylene pallet wrap contains a moisture barrier to help protect all packaged components and keep out the most inclement weather during shipping and storage. The end panel of the pallet cover contains important information regarding the snowplow model and the plow s serial number. Both of these numbers are given together. The first three (four) digits of the number indicated is always the plow model 810 (or 8611) and the entire number is the serial number (Ex: or ). The shipping document is also attached to the end panel. Be sure to retain this list for your records. SNOWPLOW SERIAL NUMBER: HYDRAULIC PUMP SERIAL NUMBER: 5

6 TECHNICAL SPECIFICATIONS PART SPECIFICATION Length 6 (8 ) 102 (8 6 ) Thickness 12 gauge 11 gauge Height Reinforcement 4 1/4" MOLDBOARD Cutting Edge 1/2 x 6 5/8 x 6 Finish Powder Coat White WINGS A-FRAME PUMP MANIFOLD Trip Mechanism (4) 3/8 hooked extension (6) 3/8 hooked extension Length Thickness 11 gauge 7 gauge Height Reinforcement 1 1/4" Cutting Edge 1/4 X 10 3/8 X 12- T1 1/2 T1 Finish Powder Coat White Material Rectangular Tube & Channel Type Hitch Pins 3/4 x 6 Yellow Zinc Finish Powder Coat Black Construction Steel Housing w/ Clear Plastic Tank Type Internal Gear Pump Size 2.5cc 3.1cc Motor 12V Starter Weight 32 lb. Mount A-frame Install w/ hex head screws Reservoir Capacity 2 qts. Controls Toggle & Rocker Construction Valves Switch/Joystick Red Anodized Aluminum Black Anodized Aluminum Electro-hydraulic cartridge PART SPECIFICATION Angle Cylinders 2 Stroke Ram Diameter 1-3/4 2 Bore Diameter 2 2-1/4 Raise/Lower Cylinders 1 CYLINDERS Stroke 4-5/8 Ram Diameter 1-1/4 Bore Diameter 3 3-1/2 Slide Box Cylinders 2 Stroke 13-15/ /16 Ram Diameter 1 1-1/8 Bore Diameter 1-1/2 1-3/4 Type Low profile w/ turn signals Measurements 12 W x 5 H x 5-1/4 D PLOW HEADLIGHTS PLOW SPECS. Housing Plastic Composite Bulb Type High/Low Sealed Beam Halogen 12V Rectangular Switch Type Integrated On/Off Control Station Switch Weight* 1047 lbs lbs. Amperage Draw** 155A 175A Compact Width 6 (8 ) 102 (8-6 ) WidePass 132 ( (10 ) Width 3 ) BucketBlade Width 111 ( -3 ) 118 ( -10 ) Adjustable Plow Shoes (2) Heavy-Duty Cast Steel Mount Mechanism Hydraulic Power Switch Standard Control Station Rocker Switch/Joystick Optional Control Station Touchpad * Weight does not include undercarriage. ** Amperage Draw specifications are based on snowplow lift operation, at a shop temperature of 65 F, using Blizzard Rapid Action Hydraulic Oil. Amperage will vary with temperature, oil viscosity and meter accuracy. Deadheading a plow function will result in significantly increased amperage. Blizzard Corporation reserves the right, under its Continuous Improvement Policy, to change construction or design details and furnish equipment when so altered without reference to illustrations or specifications. 6

7 TORQUE SPECIFICATIONS Grade Identification Marking for J42-Grade 5 Bolt Grade Identification Marking for J42-Grade 8 Bolt SAE J42 Grade 5 SAE J42 Grade 8 Nominal Nominal Clamp Loads Tightening Torque Clamp Loads Tightening Torque Thread Size Thread Size (lbs) Lubricated Dry (lbs) Lubricated Dry 1/4-20 2,000 6 ft-lbs 8 ft-lbs 1/4-20 2,850 ft-lbs 12 ft-lbs 5/ , ft-lbs 18 ft-lbs 5/ , ft-lbs 25 ft-lbs 3/8-16 4,50 23 ft-lbs 31 ft-lbs 3/8-16 6,50 32 ft-lbs 44 ft-lbs 7/ , ft-lbs 50 ft-lbs 7/16-14, ft-lbs 70 ft-lbs 1/2-13, ft-lbs 75 ft-lbs 1/ , ft-lbs 107 ft-lbs / , ft-lbs 10 ft-lbs / , ft-lbs 154 ft-lbs 5/ , ft-lbs 151 ft-lbs 5/ , ft-lbs 211 ft-lbs 3/ , ft-lbs 266 ft-lbs 3/ , ft-lbs 376 ft-lbs 7/8-2, ft-lbs 430 ft-lbs 7/8-41, ft-lbs 606 ft-lbs , ft-lbs 640 ft-lbs , ft-lbs 00 ft-lbs Grade Identification Marking for Metric-Grade 8.8 Bolt Grade Identification Marking for Metric-Grade 10. Bolt Metric Class 8.8 Metric Class 10. Diameter Diameter Clamp Loads Tightening Torque Clamp Loads Tightening Torque (mm) (mm) (Pounds) Lubricated Dry (Pounds) Lubricated Dry 5 1,38 3 ft-lbs 5 ft-lbs 5 1,87 5 ft-lbs 7 ft-lbs 6 1,65 6 ft-lbs 8 ft-lbs 6 2,812 8 ft-lbs 11 ft-lbs 7 2, ft-lbs 13 ft-lbs 7 4, ft-lbs 1 ft-lbs 8 3,57 14 ft-lbs 1 ft-lbs 8 5, ft-lbs 27 ft-lbs 10 5, ft-lbs 37 ft-lbs 10 8, ft-lbs 53 ft-lbs 12 8,243 4 ft-lbs 65 ft-lbs 12 11,76 70 ft-lbs 2 ft-lbs 14 11, ft-lbs 103 ft-lbs 14 16, ft-lbs 148 ft-lbs 16 15, ft-lbs 167 ft-lbs 16 21, ft-lbs 231 ft-lbs 18 1, ft-lbs 22 ft-lbs 18 26, ft-lbs 317 ft-lbs 20 24, ft-lbs 325 ft-lbs 20 34, ft-lbs 450 ft-lbs Turns Size N/A N/A / / / / JIC Flare Torque Values Ft-lbs Assembly steps min.max 1. Make sure the tubing and threads are clean. 2. Lubricate the threads with 10W hydraulic oil. 3. Hand tighten the nut/sleeve to approx. 30 in-lbs. 4. Make alignment marks on the nut and fitting. 5. Tighten to turn or torque specification. 6. When fully tightened, make a 2 nd set of alignment marks at the fully tighten positioned. NOTE: Torque values specified are for threads lubricated with 10W hydraulic oil. Over tightening will reduce the clamping force resulting in loss of seal and reduction of flow. Size O-Ring Boss Torque Values Ft-lbs Assembly steps min.max Verify the port, o-ring, sealing surfaces and threads are clean and free of damage. 2. Lubricate the threads and the o-ring with 10W hydraulic oil. 3. For an adjustable O.R.B., completely back off the lock nut and washer. 4. Hand tighten the fitting until it contacts the port spotface. Point the elbow or tee in the desired direction and hold. 5. Torque to specification. NOTE: Torque values specified are for threads lubricated with 10W hydraulic oil. 7

8 MOLDBOARD & A-FRAME ASSEMBLY 1. Remove dust cap from both of the slide box cylinders located at the center/rear of the moldboard. Attach one /16"-18 x /16"-18 male O.R.B. connector to each of the base ports (#8 & #) and to each of the rod ports (#7 & #10). NOTE: All of the hydraulic adapters can be found packaged with the manifold assembly. 2. Connect hoses (60224) to each of the hydraulic adapters on the cylinders. NOTE: Review the label on each hose for the appropriate part number 3. Position the pivot beam and A-frame, near the mount locations at the rear of the blade. Place the right and left group of hydraulic hoses (connected to the slide box cylinders) through the 1-1/2" diameter rubber grommet openings in the front face of the pivot beam. See the diagram to the right. Feed each group of hoses (two per side) through the grommets in the pivot beam and up through the openings in the A- frame. Positioning the hoses through the pivot beam supports the hoses while the snowplow is in use and prevents them from dragging on the ground. 4. Position the pivot beam between the two support ribs until the connecting points on the beam align with those on the plow. Insert one 3/4" DIA. x 3" clevis pin (5006) through each mounting hole and secure them with 1/4" DIA. x 1-1/2" cotter pin (61357). NOTE: Mount the kickstand to the end of the pivot beam (driver s side) using the 1/2"-13 x 4-1/2" bolt provided. The spring, bushing and lock nut are located on the inside of the pivot beam. Review the diagram to the right. To pivot the kickstand, pull the spring loaded leg out & rotate it until the pin locks into place. Adjust the foot on the stand arm so the height of the A-frame, at its mount points, is 12-1/2" to level ground. Tighten both of the top lock nuts on the kickstand. 12-1/2" NOTE: To prevent the kickstand from hitting the ground before the snowplow cutting edges, causing stress on the kickstand, adjust the kickstand foot approximately 1/8" short of level ground. This procedure will provide clearance for the kickstand when the snowplow is lowered with the kickstand in the down position. Spring Loaded Adjustable Pivot Beam Kickstand 1/8" Ground Clearance 8

9 MOLDBOARD & A-FRAME ASSEMBLY 5. Position each angle cylinder with the rod end of the cylinder in the pivot beam and the hydraulic hose port facing away from the A-frame. Secure the cylinder to the pivot beam with a 3/4" x 5" clevis pin (41051) and a 1/4" x 1-1/2" cotter pin (61357). Extend each cylinder rod until the cylinder base mounting hole aligns with the hole on the A-frame angle cylinder bracket. Insert another clevis pin and secure it with a cotter pin. 6. Remove the dust cap from both of the hydraulic angle cylinder ports and attach one /16"-18 x /16"-18 0 adjustable elbow O.R.B. adapter (60005) to each port. Each adapter should be angled toward the top of the moldboard. Connect one 3/8" x 24" (26" for 8611) hydraulic hose (6001 or 60223) to each angle cylinder adapter. Be careful not to over tighten the hose connections. Route both hoses over the TOP of each cylinder. This will prevent them from hanging or being pinched. 7. Position each angle cylinder with the rod end of the cylinder in the pivot beam and the hydraulic hose port facing away from the A-frame. Secure the cylinder to the pivot beam with a 3/4" x 5" clevis pin (41051) and a 1/4" x 1-1/2" cotter pin (61357). Extend each cylinder rod until the cylinder base mounting hole aligns with the hole on the A-frame angle cylinder bracket. Insert another clevis pin and secure it with a cotter pin. 8. Remove the plastic dust caps from the hydraulic lift cylinder ports. Attach one /16"-18 x /16" adjustable elbow O.R.B. adapter (60272) to the driver s side port (base end) and one /16"-18 x /16"-18 male O.R.B. connector adapter (60007) to the passenger s side port (rod end). Once the adapters have been installed on the cylinder, connect the hydraulic hoses. NOTE: Position the 45 fitting in the cylinder port so that the hoses install directly in the center of the A-frame access holes. A hose installed too close to the edge of the opening may work itself free with the operation of the lift cylinder and/or movement of the plow. The 45 adapter receives a 3/8" x 17" hydraulic hose (60273). Connect the 45 angle on the hose to the hydraulic adapter on the cylinder. The male connector adapter receives a 3/8" x 15" hydraulic hose (60274). Tighten the 45 end of the hose to the hydraulic adapter on the cylinder. Both hoses should be routed through the triangular openings in the A-frame Manifold Port # Manifold Ports #3,4,7,8, & Manifold Port #2 - Angle Cylinders Manifold Ports #3,4,7,8, & 10 - Lift Cylinder Rod End -Slide Box Cylinders (810 only) Lift Cylinder Base End - Slide Box Cylinders (8611 only)

10 MOLDBOARD & A-FRAME ASSEMBLY. Remove the draw latch mount pin, spacer & cotter pin from the draw latch assembly. By removing this pin, the inner draw latch plates can swing free. Remove the inner draw latch plate lift cyl. mount pin. Position the plates on either side of the lift/lower cylinder rod and insert the pin through the plates and cylinder rod. With the cylinder connected to the inner draw latch plates, rotate the draw latch assembly toward the draw latch mount holes on the A-frame. Align the holes in the outer draw latch plate with those of the inner draw latch plates and the A-frame. NOTE: The A-frame latch, located at the rear/center of the A-frame, should be raised up to insert the draw latch mount pin. Pull the A-frame latch pull pin out and rotate the latch counterclockwise if it is locked into position. Secure the assembly to the A-frame by replacing the draw latch mount pin, spacer and cotter pin. Reset the A-frame latch so the A-frame latch pull pin locks into place. 10. Assemble the manifold. The manifold, pump and coil harness have been connected at the factory; however, the manifold contains several components that you will need to install prior to securing the assembly to the A- frame. Each of the hose ports on the manifold are covered with stretch wrap. Remove the wrap and install the appropriate fitting in its respective port. NOTE: DO NOT let any foreign objects enter into the open ports. The valves can become contaminated and greatly hinder the plow s performance. Torque to proper specifications. NOTE: All ports are identified by a stamped number on the manifold. The numbers also identify the hydraulic functions, which can be referenced on the label under the hydraulic pump and manifold cover. 11. Align the mount holes in the pump with the holes in the hinged bracket, located on the A-frame. NOTE: Before mounting the pump, angle the hinged bracket as needed and tighten the bracket hardware to lock it in place. CAUTION: When installing the manifold between the mount brackets on the A-frame, hold the manifold at the sides of the block. Never handle the manifold by coils. Doing so can cause a solenoid cartridge to bend, causing the cartridge to stick when activated. Secure with 3/8"-16 x 3/4" hex head cap screw and 3/8" flat washer through the top mount hole in the bracket and into the pump. Insert 3/8"-16 x 1-3/4" threaded stud with 3/8"-16 locknut through the bottom mount hole in the bracket and into the pump. The threaded stud should bottom out in the pump. NOTE: A medium strength thread locker, such as Loctite 242 should be used on both of the pump mount fasteners. NOTE: The arrows shown on the manifold illustration indicate the direction the 0 adapters should be positioned to receive the hydraulic hoses. 10

11 MOLDBOARD & A-FRAME ASSEMBLY 12. Connect the hydraulic hoses to their respective adapters on the manifold. Hose P/N 6001 or Ports #1 & #2, Hose P/N Port #3, Hose P/N Port #4, Hose P/N Ports #7 & #10, Hose P/N Ports #8 & #. NOTE: All hoses, except #1 &#2 (angle cylinders) should be routed through the triangular openings in the A-frame. Position these hoses over the A-frame angle and to their respective manifold ports. NOTE: The positions for the rodand base-end slide box hoses. The hoses that operate the retract functions (rod) of the cylinders are closest to the base of each cylinder. The hoses that operate the extend functions (base) of the cylinders are closest to the rod of each cylinder. 13. Secure the manifold to the A-frame. Remove the washers, split lock washers and capscrews from the manifold and align the mount holes with the A-frame brackets. Properly replace and tighten all hardware. NOTE: A medium strength thread locker, such as Loctite 242 should be used to secure the manifold mount fasteners. Cylinders Extend Retract Appl y Loctite 14. Hook each extension spring to the receiving holes on the pivot beam and attach the opposite end of the spring to its respective spade bolts. Install the spade bolts through the extension spring mounting angle on the top rear of the blade. Secure each spade bolt by placing one 5/8" flat washer on the bolt and thread one 5/8"-11 nylon insert lock nut. Tighten each lock nut until a piece of paper can pass between the 3rd & 4th coils on the spring. 15. Install the blade guides at each end of the moldboard. Insert the capscrew through the holes at the top of the wing reinforcement rib. Tighten all screws with lock nuts. Appl y Loctite ***** IMPORTANT ***** Use Loctite 242 on bolt connections illustrated above. 11

12 SCHEMATIC A S5 B C S6 D S8 E S4 F S3 G S H S10 J S1 K S2 DELTA POWER PDL12 12_VDC DELTA POWER PDL12 12_VDC DELTA POWER DDL12 12_VDC DELTA POWER PDL12 12_VDC DELTA POWER PDL12 12_VDC S10 S2 S S4 S3 S6 S5 S8 S1 DELTA POWER PDL12 12_VDC DELTA POWER PDL12 12_VDC DELTA POWER PDL12 12_VDC ELECTRICAL SCHEMATIC LEFT SLIDE BOX RIGHT SLIDE BOX RIGHT ANGLE LIFT CYL LEFT ANGLE 2 3 RAISE LOWER PSI (2650 PSI) 3000 PSI RV PSI (2650 PSI) FC 1700 PSI 1700 PSI (2800 PSI) RV2 (2800 PSI) RV3 RV1 CV1 50 PSI CV2 50 PSI S4 S5 RV4 CV3 50 PSI CV4 50 PSI S3 T2 X S10 S S6 S8 S2 S1 X TGP P2 T1 P1 HYDRAULIC SCHEMATIC NOTE: Where applicable, Model 8611 values are in parenthesis. 12

13 HYDRAULIC GUIDE 13

14 ELECTRICAL-PLOW SIDE INSTALLATION INSTRUCTIONS 1. Connect the red power wire from the plow harness to the pump motor terminal stud. Hardware provided on pump. 2. Place the 3/8 lock washer, the black ground wire(from the harness) and the red ground wire on the coil harness (from the manifold) over the tapped hole on the pump and secure with 3/8"-16 x3/4" screw. 3. Remove the nut and washer from the Power Hitch connect/disconnect toggle switch and insert it through the back of the mounting bracket on the A-frame. Align the notches on the switch and bracket. Replace the washer and nut and tighten until the switch is firmly in place. Attach the connector on the plow harness to the switch. NOTE: Use caution when connecting, switches can break if done forcefully. The Pump Cover Installs Over The Top Of The Draw Latch Switch Bracket 4. Attach the connector on the harness to the connector on the coil harness. 5. Position the harness braid in the notch on the switch bracket and secure it with a cable tie. NOTE: The diode loop harness should be inside of the pump cover. 6. Install the pump & manifold cover by aligning the notches in the cover with the welded bolts on the A-frame brackets. Secure with clamping knob. Verify the cover is positioned over the protective toggle switch hood. Pop the front of the cover on the threaded stud and secure it with the remaining knob. 14

15 ELECTRICAL BLIZZARD HARNESS PLUG (VEHICLE) UNIVERSAL MOLD PIN COLOR FUNCTION AWG NO. BLACK GROUND 4 1 BLACK GROUND 18 2 RED 12 VOLT DC (+) 4 BROWN/WHITE PUMP SOLENOID TO RING 18 3 BROWN PUMP SOLENOID TO MOLEX 18 4 RED/WHITE RIGHT SLIDE BOX EXTEND 18 5 RED/BLACK RIGHT SLIDE BOX RETRACT 18 6 BLUE/WHITE LEFT SLIDE BOX EXTEND 18 7 BLUE/BLACK LEFT SLIDE BOX RETRACT 18 8 BLUE LEFT ANGLE 18 LT. GREEN RIGHT ANGLE WHITE LIFT ORANGE FLOAT N/A N/A N/A 13 N/A N/A N/A 14 N/A N/A N/A 15 PINK/BLACK 12 (+) VDC FUSED N/A N/A 18 WIRE COLOR (BLUE) WIRE COLOR (RED) 7 4 BLUE/BLACK BLUE ORANGE STRIPE COLOR (BLACK) PIN NUMBER STRIPE COLOR (WHITE) PIN NUMBER EXAMPLE TOP BLUE/WHITE RED/BLACK BLACK 3 12 RED/WHITE BROWN BROWN/WHITE LIGHT GREEN RED WHITE BLACK PINK/BLACK VEHICLE HARNESS PLUG (2005) FACE VIEW LOOKING AT FEMALE CONNECTOR FEMALE TERMINALS BLIZZARD HARNESS PLUG (PLOW) PIN COLOR FUNCTION AWG NO. 1 BLACK GROUND 4 N/A N/A N/A 2 RED 12 VOLT DC (+) 4 3 BROWN PUMP SOLENOID 18 4 RED/WHITE RIGHT SLIDE BOX EXTEND 18 5 RED/BLACK RIGHT SLIDE BOX RETRACT 18 6 BLUE/WHITE LEFT SLIDE BOX EXTEND 18 7 BLUE/BLACK LEFT SLIDE BOX RETRACT 18 8 BLUE LEFT ANGLE 18 LT. GREEN RIGHT ANGLE WHITE LIFT 18 WHITE LIFT ORANGE FLOAT N/A N/A N/A 13 N/A N/A N/A 14 N/A N/A N/A 15 PINK/BLACK 12 (+) VDC FUSED N/A N/A 18 PERIODICALLY APPLY NON-CONDUCTIVE DIELECTRIC GREASE WITH CORROSION PREVENTIVE COMPOUND ON ALL TERMINALS WIRE COLOR (PINK) WIRE COLOR (BLUE) 15 6 RED/WHITE BROWN LIGHT GREEN STRIPE COLOR (BLACK) PIN NUMBER STRIPE COLOR (WHITE) PIN NUMBER EXAMPLE TOP BLACK PLOW HARNESS PLUG (2005) FACE VIEW LOOKING AT MALE CONNECTOR MALE TERMINALS RED/BLACK BLUE/WHITE RED BLUE/BLACK BLUE ORANGE WHITE (DOUBLE) PINK/BLACK 15

16 ELECTRICAL-PLOW SIDE 7 (1) BRN (2) BRN (3) ORG/RED (4) WHITE (5) PNK/BLK (6) PNK/BLK A ORG/BLK B ORG/WHT C WHT D ORG/RED E LT GRN F BLU G BLU/BLK H BLU/WHT J RED/BLK K RED/WHT A B C D E TOP POWER PLOW BLIZZARD PERIODICALLY APPLY NON-CONDUCTIVE DIELECTRIC GREASE WITH CORROSION PREVENTIVE COMPOUND ON ALL TERMINALS WHT ORG/WHT ORG ORG/BLK ORG/RED (4) 6 AMP 600 VOLT DIODES WHT ORG ORG/RED F G H J K ORG/WHT ORG/BLK PLOW HARNESS (6203) ORG ORG/WHT ORG/BLK ORG/RED WHT 7 BLU/BLK 8 BLU LT GRN 10 WHT 11 ORG 15 PNK / BLK BLK 2 RED 3 BRN 4 RED / WHT 5 RED / BLK 6 BLU/ WHT

17 ELECTRICAL-PLOW SIDE A ORG/BLK BLU/BLK ORG/WHT ORG/BLK ORG WHT ORG/RED B C D E F G H J K ORG/WHT WHT ORG/RED LT GRN BLU BLU/BLK BLU/WHT RED/BLK RED/WHT PLOW WIRE HARNESS SCHEMATIC (6203) PINK/BLK ORG/RED ORG/RED WHT WHT BRN BRN LT GRN BLU PINK/BLK ORG/WHT ORG/BLK D4 ORG ORG/RED D3 WHT D1 ORG/RED ORG/BLK ORG/WHT WHT D2 ORG BLU/WHT RED/BLK RED/WHT ORG WHT ORG/WHT ORG/BLK ORG/RED 4GA, RED 4GA, BLACK WHT BRN PNK/BLK ORG WHT LT GRN BLU BLU/BLK BLU/WHT RED/BLK RED/WHT RED BLK

18 ELECTRICAL-VEHICLE SIDE CAUTION: Always attach the vehicle harness assembly with the vehicle off and the keys out of the ignition. Use caution when testing the electrical wires for the vehicle s headlight functions. INSTALLATION INSTRUCTIONS 1. Insert the connector end of the harness through the driver s side firewall access panel into the vehicle cab. Loosely position the remaining portion of the harness over the driver s side fender well and place the plug end of the harness near the bumper. NOTE: Keep the plow plug and vehicle connector pins lubricated with a liberal amount of dielectric grease. Always replace the protective weather caps when the plow is disconnected from the vehicle. 2. Attach the power contactor (solenoid) to the driver s side wheel well or engine fan guard using x 3/4" self-drilling screws. NOTE: Some model vehicles provide mounting locations for accessory components. Always mount the solenoid with the terminals facing up, for extended solenoid life. Connect the 24" black ground wire to either small terminal on the solenoid and attach the opposite end to the vehicle with a selfdrilling screw. Cut the brown/white pump activation wire on the harness to length and crimp the eyelet terminal onto it. Attach the eyelet to the remaining small terminal on the contactor. Secure it with the hardware provided on the solenoid. 3. Connect the vehicle harness ground wire to the negative terminal on the vehicle s battery. Cut the wire to length and crimp a 3/8" ring terminal on the wire. It is also recommended that the ring terminal be soldered. NOTE: The harness should be secured to the vehicle prior to taking the necessary measurement. Measure the distance needed for the power wire to reach the solenoid and properly secure an end ring terminal to it. Connect the power wire to either large terminal on the solenoid. CAUTION: Do not fasten the harness to areas that come in contact with moving engine parts or possess extreme heat. The harness could become tangled and/or melt causing electrical failure and vehicle damage. 4. Attach and solder an end ring terminal to both ends of the remaining length of the red wire. Connect one end of the wire to the open terminal on the solenoid and the remaining end to the positive terminal on the battery. 5. Position the main lighting harness with both of the truck light connectors near each truck headlight and the plow light connectors near the grill of the vehicle. 6. Plug the headlight ground/relay connector from the vehicle harness into the connector on the main lighting harness. Plug each headlight relay into the receptacles. Securely mount the receptacles to the vehicle with the terminal wires facing down and the relays facing up. Installing the relays in this position will allow moisture to drain from the relay. 7. Remove the front signal light assembly from both sides of the vehicle. Feed the violet, turn light wire, and gray, run light wire, from the main lighting harness through the opening in the signal light housing. Use a test light or ohm meter to determine the proper wires in the vehicle s electrical system to splice into. Position one end of the turn or run light wire into the splice lock connector, and attach the vehicle wire into the opposite side. Complete the splice by pinching both wires together and locking the connector. Repeat the splice procedure for the remaining wire. 8. Connect the vehicle headlights to the main lighting harness using a light conversion harness kit. Due to differences in the construction of the kits, and the various make and model vehicles Blizzard snowplows are installed on, a light conversion kit is not packaged with your snowplow. Contact your local Blizzard dealer to obtain the appropriate conversion harness kit for your vehicle.. Secure the braided harness to the vehicle. Safely route all harness lengths around the engine components and attach them to the vehicle with cable ties. Extend the plow headlight connectors, from the main lighting harness, through the grill of the vehicle and position the harness power plug and weather cap near the bumper. Cable tie the plug to the vehicle bumper or tow hook to keep the harness from hanging too low. 18

19 ELECTRICAL-VEHICLE SIDE 10. Install the remainder of the vehicle wire harness to the interior of the cab. Connect the power wire (with 15AMPFUSE) to a switched power source with a minimum of 15 amps. NOTE: The red power wire MUST be fused and switched on and off with ignition. Secure all loose wires under the dash. 11. Install the light tower. Position the arms into the receiving pockets located on the undercarriage. Each pocket has a lock pin that secures both light tower arms. Pull out and twist each handle to temporarily unlock the pins. Place the light tower into the pockets and relock the pins. See your local Blizzard dealer for complete installation instructions for your vehicle undercarriage. 12. Install the plow headlights. Align one headlight stud on the light tower tube with the mounting hole and insert the threaded stud through each. Secure the headlight with one 1/2" galvanized washer (neoprene facing up), one 7/16" external tooth lock washer and hex nut. NOTE: All snowplows are shipped with two caps that install on the ends of the light tower. Connect the terminals from the plow lights to the terminals on the main lighting harness. 13. Position the rocker switch/joystick control station on the front radius of the seat. Wrap the Velcro strap around the bench, through the 2" metal D-ring and fasten. Connect the white power connector from the vehicle wire harness to the connector on the control station. The power switch should be in the MIDDLE or OFF position. NOTE: The operation of the draw latch can only be controlled when the power switch is located in the UP position and the RAISE/LOWER rocker switch is in the neutral or center position. 14. Test your plow before using. 1

20 ELECTRICAL-VEHICLE SIDE BLIZZARD POWER PLOW B A FUSE CAP FUSE BODY SPRING FUSE 15AMP RED/WHT 2 RED/BLK 5 BLU/WHT 6 BLU/BLK 7 BLK 8 WHT 1 BRN RED ORG PNK/BLK LT GRN BLU VEHICLE HARNESS (2005) RED BRN/WHT RED GRN/YEL BLK GA BLK 4GA RED BRN RED/WHT RED/BLK BLU/WHT BLU/BLK BLU LT GRN WHT ORG PNK/BLK 20

21 ELECTRICAL-VEHICLE SIDE PNK/BLK ORG WHT LT GRN BLU BLU/BLK BLU/WHT RED/BLK RED/WHT BRN BRN/WHT 4GA RED BLK 4GA BLK VEHICLE HARNESS SCHEMATIC (2005) NOTE: ALL GROUNDS HAVE BLACK WIRE BLACK PNK/BLK ORG WHT LT GRN BLU BLU/BLK BLU/WHT RED/BLK RED/WHT BRN BLK GRN/YEL BLK B A RELAY LIGHTING HARNESS GRN/YEL 1 BLK 2 RED PNK/BLK ORG WHT LT GRN BLU BLU/BLK BLU/WHT RED/BLK RED/WHT BRN BLK

22 ELECTRICAL-VEHICLE SIDE TRUCK LIGHT HARNESS C B A C YEL B WHT/RED A LT GRN C = HIGH BEAM (YELLOW) B = COMMON (WHITE/RED) A = LOW BEAM (L GREEN) TRUCK LIGHT BULB A B C A LT GRN/RED B WHT/RED C YEL/RED A = LOW BEAM (L GREEN/RED) B = COMMON (WHITE/RED) C = HIGH BEAM (YELLOW/RED) WATER RESISTANT SPLICE LOCK CONNECTOR (USED IN INSTALLATION) OTHER WIRE OTHER GRAY WIRE WIRE WATER RESISTANT SPLICE LOCK CONNECTOR (USED IN INSTALLATION) OTHER WIRE OTHER VIOLET WIRE WIRE A WHT B BLK C PNK D GRY E LT GRN/BLK F YEL/BLK A B C D E F A BLK B GRN/YEL A B A B 86 87a a a 87a1 85 B MAIN LIGHTING HARNESS (2005) A B C D E F A WHT B BLK C PNK D GRY E LT GRN/BLK F YEL/BLK JACKET MATERIAL BLACK NYLON BRAID 87 YEL/BLK 86 BLK/WHT 30 YEL 85 GRN/YEL 87a1 YEL/RED 871 LT GRN/BLK 861 BLK/WHT 301 LT GRN 851 GRN/YEL 87a1 LT GRN/RED 87 YEL/BLK 86 BLK/WHT 30 YEL 85 GRN/YEL 87a1 YEL/RED 871 LT GRN/BLK 861 BLK/WHT 301 LT GRN 851 GRN/YEL 87a1 LT GRN/RED a 87 87a a a1 B WATER RESISTANT SPLICE LOCK CONNECTOR (USED IN INSTALLATION) OTHER WIRE OTHER PINK WIRE WIRE C YEL B WHT/RED A LT GRN TRUCK LIGHT HARNESS C B A A LT GRN/RED B WHT/RED C YEL/RED C = HIGH BEAM (YELLOW) B = COMMON (WHITE/RED) A = LOW BEAM (L GREEN) TRUCK LIGHT BULB A B C A = LOW BEAM (L GREEN/RED) B = COMMON (WHITE/RED) C = HIGH BEAM (YELLOW/RED) WATER RESISTANT SPLICE LOCK CONNECTOR (USED IN INSTALLATION) OTHER WIRE GRAY WIRE OTHER WIRE 22

23 ELECTRICAL-VEHICLE SIDE YEL/RED YEL YEL/BLK LT GRN/RED LT GRN A B B GROUND BLK C RIGHT TURN PNK C D E F C YEL HIGH BEAM FEED B WHT/RED COMMON A LT GRN LOW BEAM FEED B WHT/RED COMMON C YEL/RED HIGH BEAM GRY VIO FROM VEHICLE HARNESS BLK BLK/WHT BLK/WHT GRN/YEL GRN/YEL A COMMON WHT B GROUND BLK A B C RIGHT TURN PNK D PARK-RUN GRY E LOW BEAM LT GRN/BLK F HIGH BEAM YEL/BLK PNK LT GRN/BLK YEL/RED YEL YEL/BLK LT GRN/RED LT GRN LT GRN/BLK PLOW LIGHT A COMMON WHT D PARK-RUN GRY E LOW BEAM LT GRN/BLK F HIGH BEAM YEL/BLK TRUCK HARNESS A LT GRN/RED LOW BEAM TRUCK LIGHT MAIN LIGHTING HARNESS SCHEMATIC (2005) a 87 87a 87 87a 87 87a PLOW LIGHT C D E F TRUCK HARNESS C YEL HIGH BEAM FEED B WHT/RED COMMON A LT GRN LOW BEAM FEED A LT GRN/RED LOW BEAM B WHT/RED COMMON C YEL/RED HIGH BEAM TRUCK LIGHT GRY A B 23

24 POWER HITCH INSTRUCTIONS Prior to operating your Power Plow snowplow, review the Mounting and Dismounting Instructions label on the back of the driver s side moldboard. NOTE: If at any time the Mounting and Dismounting Instructions label, or any other label attached to your snowplow become illegible, promptly replace them. CONNECT/DISCONNECT Power Hitch Switch Adjustable Kickstand Undercarriage Push Beam A-Frame Latch CONNECT/DISCONNECT Power Hitch Switch A-Frame Latch Lock Pin Draw Pin Adjustable Kickstand Power Hitch 24

25 TESTING YOUR PLOW 1. Fill the hydraulic pump reservoir with BLIZZARD SNOWPLOW RAPID ACTION HYDRAULIC OIL until it is approximately 3/4" from the top of the tank. Replace the cap on the reservoir. Remove the weather caps from each of the plow and vehicle harnesses and connect the plugs. Start the vehicle and turn the power switch on the control station in the cab to the ON position. 2. To raise the POWER HITCH on the snowplow, turn the power switch on the control station to the UP or ON position. Push and hold the toggle switch on the A-frame upward into the CONNECT position. Notice the action of the fluid in the reservoir. By activating the initial hydraulic function, the fluid begins to fill the system. Push and hold the toggle switch in the DISCONNECT position, the Power Hitch will lower. Refill the reservoir until the fluid is approximately 3/4" from the top of the tank. 3. Align the Power Hitch on the A-frame below the push beam, with the receiver plates in line with the receiver plates on the undercarriage. Pull out the A-frame latch pin and rotate the A-frame latch clockwise until the latch is resting on the draw pin. Move the snowplow in position by activating the Power Hitch connect switch and release. WARNING: Always use caution when operating the Power Hitch CONNECT/DISCONNECT switch. Keep your hands and feet away from the operation of the Power Hitch and the main blade. The action of the Power Hitch moves the snowplow in position for proper attachment to the vehicle. Failure to follow this caution may result in serious injury or death. The Power Hitch will rise until it hits the push beam and the draw latch fingers will pull the plow into the vehicle. The receiver plates on the plow and vehicle are now positively aligned. Rotate the A-frame latch counterclockwise until the latch is in the raised position. NOTE: The A-frame latch pin should always lock in place. Do not set the pin past the lock point on the A-frame. Insert the two hitch pins through the mounting holes on the A-frame and secure each with one hair pin cotter. Draw Latch in Transport Position 25

26 TESTING YOUR PLOW 4. Return to the interior of the vehicle. Test the remaining functions of the snowplow. The system power on the control station should be in the ON position. Raise the plow to its maximum height by pulling the joystick back (or down). Initiate the driver s side wing by pushing and holding the LEFT WING EXTEND rocker switch until the wing pivots forward. Notice the staggered pace the wing extends. The hydraulic fluid is filling the hose and replacing the air in the system. Push and hold the LEFT WING RETRACT rocker switch to return the wing. Continue testing the remaining rocker switch functions. To lower the plow to the ground, push the joystick ahead (or up). NOTE: The float function is activated when the joystick is pushed forward in the lower/float position and held there for.5sec. The LED light will come on when the snowplow is in float mode. Initiate the driver s side wing by pushing and holding the LEFT WING EXTEND rocker switch until the wing pivots forward. With both wings retracted, monitor the fluid level in the reservoir and fill to 3/4" from the top of the tank if needed. Also, look for any hydraulic fluid leaks around the manifold, pump, hydraulic hoses and all cylinders. 5. Check that the vehicle and plow headlights are in proper working condition including the turn signals. If necessary, adjust the plow headlight beams with the plow in the raised position. 26

27 MAINTENANCE MAINTENANCE PERIODICALLY YEARLY Check fasteners for tightness. Torque to specifications. X Check hoses for wear and leaks. X Check cylinders for leaks; inspect rod ends for corrosion & pitting X Lubricate all exposed cylinder rod ends with liquid white lithium grease to prevent corrosion. X Check cutting edges and plow shoes for wear. NOTE: Do not discard plow shoe washers, these should be retained for different shoe X adjustments. Clean and lubricate all electrical plugs and connections with dielectric grease. Clean and install all dust caps prior to storing. X X Lubricate all pins and bushings, inner slide box and A-frame latch with NLGI Grade 2 multi-purpose lithium complex grease with molybdenum X X (MPGM) ) to maintain consistent operation Clean and paint all scratches or exposed metal with Blizzard touch-up paint X X Check the hydraulic oil level. Fill with fluid to 3/4 from the top of the reservoir. Do not exceed this level. Never mix different types of fluid. X Remove and properly discard the fluid from the pump reservoir. Clean the pump filter and replace the hydraulic oil to within 3/4" from the top of the reservoir. Changing the fluid annually will prolong the life of your X pump and manifold. Never mix different types of hydraulic oil. Check the trip spring adjustment. Properly adjusted tension will allow a sheet of paper to pass between the 3rd and 4th coils of the spring. X Adjust the wing spring as needed or install an optional second extension spring for increased return speed. X Clean snow & ice build-up from the pump and manifold cover. X Pressure wash and dry the entire snowplow prior to storing X Cover the snowplow with a tarp if stored outside. This will protect your plow from sun fading and inclement weather which can lead to accelerated corrosion. X REMOVING FROM STORAGE 1. Perform all regular maintenance. 2. Replace the hydraulic oil in the pump reservoir. Prolonged storage could result in condensation build-up. 3. Follow the mounting procedure on the Power Hitch label. 4. Initiate all of the functions. Monitor the fluid level in the reservoir and fill to 3/4 from the top of the tank as necessary. 5. Adjust the snowplow headlights as needed. 27

28 TROUBLESHOOTING PROBLEM CAUSE SOLUTION Plow harness may not be properly connected to the vehicle harness. Verify the harnesses are properly connected. Pump will not run. Power or ground cables to the battery, pump or solenoid may not be properly connected. Properly connect all cables. Clean and lubricate with dielectric grease. If power does not resume, check the continuity of all cables to find the break. Pump will not run, power to the solenoid. Pump will not run with power to the solenoid. Brown/white activation wire and ground are properly connected. Pump will not turn off. Do not allow the pump motor to run continuously. Unplug the harness until the solenoid can be tested or a Blizzard Dealer can diagnose the problem. Pump runs but plow functions are slow. A-frame latch will not move. Plow will not lift. Pump works properly. The black ground wire and brown/white activation wire on the solenoid are not properly connected. The red, hot wire to the pump motor is not properly connected. Solenoid may be damaged. Short in the joystick control or wire harness. Fluid level in the pump reservoir is low. Fluid is leaking. System pressure may be set too low. Increasing the pressure excessively will increase the amperage draw. This could damage the vehicle harness. Amperage from the vehicle s alternator is too low. Pump filter may be clogged. Draw latch is binding the A-frame latch. Control station in the cab may not be properly connected A-frame latch is in the (down) locked position. Diode loop harness may be corroded or could have failed. Properly connect both cables. Test for power by initiating any joystick function except the float. NOTE: The POWER rocker switch must be in the ON position to properly test any plow function. If the solenoid is grounded and no power exists, diagnose the plow & truck harnesses. Connect red wire and check the black ground wire. If problem is not resolved, the solenoid could be inoperable or the pump motor may be worn. Replace the solenoid if there is no power to the pump. Replace the pump motor if it is receiving power. Disconnect the brown/white activation wire from the solenoid. If the problem is not resolved, replace the solenoid. Disconnect the joystick in the cab. If the pump turns off, there is a short in the electrical system. Add fluid to within 3/4 from the top of the tank. Check for leaks around the pump, manifold and cylinders. Adjust the pressure. Remove the hex cap on top of the pump and turn the screw clockwise. Proper system pressure should be set at 2400PSI. Test functions and repeat procedure as needed. Repair or replace vehicle alternator. System amperage draw is 155A (175A for 8611) at 1500PSI. Remove the pump tank and thoroughly clean the filter. Lower the draw latch to relieve binding on the A-frame latch and reposition the A-frame latch as needed. Connect the power connector from the control to the vehicle harness. Lift the A-frame latch into the raised position. Clean diode loop harness thoroughly and/or replace. 28

29 PROBLEM CAUSE SOLUTION Plow will not lift. Pump works properly. Plow will not lift with magnification to the S6 coil. Plow will not stay angled when plowing. Plow will not angle, pump works. Wing will not stay angled when plowing. Wing will not move, pump works. Coils on the manifold may be damaged. Hydraulic lock in the manifold. This occurs if the voltage is too low on the coils should be 10 volts. Solenoid cartridge valve may be contaminated. The angle pressure relief valve is set too low. NOTE: Increasing the pressure relief valve will cause damage to your plow. Do not set the pressure relief greater than 3000 PSI. Review all probable causes above. The angle pressure relief valve is set too low. NOTE: Increasing the pressure relief valve will cause damage to your plow. Do not set the pressure relief greater than 1700PSI (2650PSI for 8611). Control station, harness or cables may be loose or improperly connected. Hydraulic lock in the manifold has occurred. No power to the coils. Coils are receiving power. TROUBLESHOOTING Remove the S6 coil from the cartridge valve. Position a screwdriver inside of the coil and push the draw latch connect/disconnect toggle switch upward. The screwdriver should be magnetically drawn to the coil. Replace the coil if there is no action. Loosen cartridge valve S6 to relieve pressure and retighten. DO NOT OVER TIGHTEN! Valves should be torqued to a maximum of 24 ft-lbs. Remove any foreign objects that may be obstructing proper valve operation. Replace if not operating properly after cleaning. Check the pressure relief by testing the valve inline with the cylinder. Attach a tee fitting to the angle cylinder hydraulic adapter and connect the hose and pressure gauge to the tee. NOTE: The setting should not exceed 3000PSI. NOTE: Verify coils S3 & S4 for angle functions. Test the wing pressure relief. Attach a fluid PSI gauge to the quick connect fitting on the manifold. The pressure relief should not be greater than 1700PSI (2650PSI for 8611). Verify control station, harness and all cables are securely connected. Clean if necessary. Loosen cartridge valves S & S10 or S1 & S2 to relieve pressure and retighten. DO NOT OVER TIGHTEN! Valves should be torqued to a maximum of 24 ft-lbs. Verify coils S1 & S2 (pass. side slide box retract and extend) and S & S10 (drive. side slide box retract and extend) are grounded, connected properly and receiving power. If no power is available, diagnose the harness. Review the harness schematics. If power is present, review the next step. Verify coils are magnetizing. Position a screwdriver inside of the coil. When the respective function is activated, the screwdriver is drawn to the side of the coil. If the coil is not drawn to the screwdriver, replace the coil. If power is present, review the next step. 2

30 TROUBLESHOOTING PROBLEM CAUSE SOLUTION Wing will not move, pump works. Solenoid cartridge may be contaminated or damaged. A bent cartridge will not allow the valve to move freely inside of the cartridge. Plow lowers too slow. Plow drops sporadically. Headlights will not switch from the vehicle to the snowplow. Variable flow control valve is not adjusted properly. Review all probable causes for plow will not lift Variable flow control valve is opened too far. No power or ground to the headlight relay. Determine a damaged cartridge valve by reversing the driver s side and passenger s side cartridge valves. Replace valve if necessary. Turn flow control valve counterclockwise in small increments and test. NOTE: Never make adjustments when the plow is in the raised position! Fluid pressure will make the valve difficult to adjust and serious injury or death can occur from a falling plow. Verify S5 coil (float) or S5 & S8 coils (disconnect) for magnetism. Turn clockwise 1/16 of a turn and test. NOTE: Never make adjustments when the plow is in the raised position! Fluid pressure will make the valve difficult to adjust and serious injury or death can occur from a falling plow. Verify the headlight/ground relay connector is connected. If the connector is properly attached replace the headlight relay(s). 30

31 NOTES 31

32 MOLDBOARD & WING PARTS 26/27 27/ A / , A 32

33 MOLDBOARD & WING PARTS REF PART NUMBER QUANTITY DESCRIPTION Moldboard Weldment Label, WARNING! (Blz1005) Decal, Center Moldboard (Blz1070) Label, Power Hitch Mounting & Dismounting (Blz1077) Cutting Edge, Moldboard (1080) Bolt, Carriage, 1/2"-13 x 1-1/2" Gr Bolt-Carriage 5/8-11 UNC x 2" Gr Nut, Flanged Lock, 1/2"-13 Z Nut, Flanged Lock, 5/8"-11 Z Wing Weldment, Driver s Side Decal, Wing, Driver s Side Cutting Edge, Weldment Driver s Wing (T1) Slide Box, Weldment Drivers Label, Warning! Multiple Pinch Points (Blz1068) 13A Plow Shoe Asm, Heavy-Duty Cast Iron (8-3/8" Shaft): (1) - 13 & 15, (18) Spacer, 1-1/8" I.D., 1-5/8" O.D. x 1-1/2" YZ Washer, 1" Flat YZ Pin, Linch, 7/16" x 1-3/4" YZ Label, Serial Number, Sequentially Numbered (Blz104) Screw, 5/16"-18 x 2-1/4" HHCS Gr8 YZ Pin, Slide Box Stop, 1" x 3-3/4" (with 3/8" Dia. hole) Pin, Slide Box Stop, 1" x 4-1/8" (with 3/8" Dia. hole) Nut, 5/16"-18 Top Lock Z 20A Plow Guide Assembly:(2)-20 & Screw, 5/16"-18 x 1" HHCS Gr5 Z Nut, 5/16"-18 Nylock Z Wing Weldment, Passenger s Side Decal, Wing, Passenger s Side Cutting Edge, Weldment Passenger s Wing (T1) Bolt, Carriage, 1/2"-13 x 3-1/2" Gr8 P Bolt, Carriage, 1/2"-13 x 5" Gr8 P Bolt, Carriage, 1/2"-13 x 4-1/2" Gr8 P Bolt, Carriage, 1/2"-13 x 5-1/2" Gr8 P Bolt, Carriage, 1/2"-13 x 6-1/2" Gr8 P Slide Box, Weldment Passenger Bolt, 5/8"-11 x 7-3/8" Spade Gr8 Z Spring, Extension, 13" O.A.L. x 2" O.D. x 5/16" Spring, Extension, 15-1/4" O.A.L. x 2-3/8" O.D. x 3/8" Pin, Clevis, 5/8"DIA.x 3" YZ Pin, Spring, 1/4" Dia. x 1-1/4" Pin, Wing/Slide Box Pivot, 3/4" Dia. x " Pin, Wing/Slide Box Pivot, 1" Dia. x 11-1/8" Plug, 2-51/64" O.D., 2-/32" I.D. x 1/2" Black Polyethylene Hydraulic Cylinder, Slide Box Extend/Retract Nut, 5/8"-11 Top Lock Z Hydraulic Adapter, /16"-18 x /16"-18 Male O.R.B Hydraulic Hose, 3/8" x 36" (Ports #7, 8, & 10) Slide Box Extend/Retract Cap, 5/8" I.D., 3/4" O.D. x 1", Black Vinyl Pin, Hydraulic Cylinder Base End 5/8" Dia. x 11-1/2" (with 1/4" Dia. hole) - Slide Box Extend/Retract Pin, Hair Cotter, 1/8" Dia. x 2-5/8" Z Bolt, Spade, 5/8"-11 x 6-3/8" Gr8 Z Washer, 5/8" SAE Hardened YZ Nut, Nylock, 5/8"-11 Type NE Hydraulic Adapter, /16"-18 x /16" Adjustable Elbow O.R.B. 33

34 A-FRAME & PIVOT BEAM PARTS A A A

35 A-FRAME & PIVOT BEAM PARTS REF PART NUMBER QUANTITY DESCRIPTION Pivot Beam Weldment Pin, Cotter, 1/4" x 1-1/2" Z 3A Kickstand Assembly Includes Ref Kickstand Foot Weldment Kickstand Leg Weldment Screw, 1/2"-13 x 1-1/4" HHCS Gr8 YZ Washer, 1/2 Flat SAE Hardened Nut, 1/2"-13 Top Lock Z Screw, 1/2"-13 x 4-1/2" HHCS Gr8 YZ Spring, Compression, 2" O.A.L. x 1.101" O.D. x 0.207" Dia Bushing, 1.13" O.D. x 0.53" I.D. x 3/8" Stepped Pin, 3/4"Dia. x 3" Clevis YZ Pin, 3/4"Dia. x 5" Clevis YZ Screw, 1"-8 x " HHCS Gr8 P Nut, 1"-8 Top Lock Z Grommet, 1-1/2" I.D., 2-1/8" O.D. Black Rubber, 60 Durometer Hydraulic Cylinder, Plow Angle Hydraulic Hose, 3/8" x 24" Plow Angle (Ports #1 &#2) Hydraulic Hose, 3/8" x 26" Plow Angle (Ports #1 & #2) Hydraulic Adapter, /16"-18 x /16"-18 0 Adjustable Elbow O.R.B Hydraulic Cylinder, Plow Raise/Lower Pin, 3/4" Dia. x 6" Clevis YZ Hyd. Hose (Port #3), Straight/45, 3/8" x 17" - Raise/Lower, Extend Hydraulic Adapter, /16"-18 x /16" Adjustable Elbow O.R.B Hyd. Hose (Port #4), Straight/45, 3/8" x 15" - Raise/Lower, Retract Knob, 3/8-16 Nylock Clamping Screw, 3/8"-16 x 3/4" HHCS Gr8 YZ Washer, 3/8" SAE Hardened Nut, 3/8"-16 Jam Nylock Z, Type NTE Stud, 3/8"-16 x 2-1/8" Threaded Hinge Weldment, Pump Mount Screw, 3/8"-16 x 2" HHCS Gr8 YZ Nut, 3/8"-16 Top Lock Z Switch, Toggle, DPDT, (On)-Off-(On), Draw Latch Connect/Disconnect 33A A-Frame Assembly Includes 2-31,33, A-frame Weldment Pin, 3/4" x 6" Hitch YZ Pin, /64" Dia. x 2-11/16" Hair Cotter Z Ring, Standard Split, 1.48" O.D Spring, Draw Latch Lock Pin Pin, 3/8" Dia. x 1-3/4" SS Screw, 5/16"-18 x 3/4" HHCS Gr8 YZ Washer, 5/16" Split Lock YZ High-Alloy Bushing, A-frame Pivot, Replaceable Label, Power Hitch Connect/Disconnect Switch (Blz1037) 43A Draw Latch Assembly Includes Ref 43-56, 2 (Qty1) Outer Draw Latch Plate Weldment, Driver s Side Pin, Draw, 1" Dia. x 6-1/2" (with 13/64" Dia. Cotter Pin Hole) YZ Pin, Cotter, 3/16" Dia. x 2-1/2" Z Screw, 3/4"-10 x 4-1/2" HHCS Gr8 YZ Inner Draw Latch Plate Pin, 1" x 4-21/32"Draw Latch Mount (To A-frame) YZ Draw Latch Arm Weldment Draw Latch Finger Weldment Pin, 3/4" x 2-1/2", Draw Latch Arm Pivot Pin/Hydraulic Cylinder Rod End Bushing, 1-1/4" O.D. x 1-1/16" I.D. x 1-1/2" YZ Outer Draw Latch Plate Weldment, Passenger s Side Pin, 3/4" DIA.x 3-41/64" Clevis YZ Spacer, 1" O.D. x 25/32" I.D. x 5/8" YZ Nut, 3/4"-10 Top Lock Z Cover, Pump/Manifold Blk 35

36 POWER UNIT PARTS A A ,

37 REF PART NUMBER QUANTITY DESCRIPTION 1A Hydraulic Pump Assembly Includes Ref 1-2 & Reservoir Motor, 12VDC Seal Kit Pump Assembly, 2.47CC/REV Pump Assembly, 3.14CC/REV Filter Clamp, Reservoir Reservoir, Screw Grommet Breather Relief Valve Asm Tube, Plastic Suction Elbow Tube, Plastic Return Elbow Brush Kit 16A Manifold Assembly Manifold Block (with Cross Port Relief), Red Anodized Aluminum Manifold Block (with Cross Port Relief), Black Anodized Aluminum Plug, Hollow Hex, -6 SAE Hydraulic Adapter, /16"-18 0 Swivel Elbow Hydraulic Adapter, /16"-18 x /16"-18 Male Extra Long Elbow Piston Assembly Valve, Check, 50 PSI Coupling, Test Port, 7/16"-20 O.R.B Valve, Spool, Three-Way, Two Position Coil Harness Assembly Includes (7), (1), (1) Coil, PDL10V DC Nut, Hex Jam, 1/2"-20 YZ Connector, Electric, Male, Plastic Seal, Cable, Silicone, Orange (18 AWG) Cavity Plug, Silicone, White(18-16 AWG) Terminal, Male (18-16 AWG) Terminal, End Ring, 3/8" I.D. Copper, 6 Gauge Valve, Relief, 1700 PSI Valve, Relief, 2800 PSI Valve, Relief, 1500 PSI Valve, Relief, 2650 PSI Valve, Spool, Four-Way, Two Position C.C Valve, Relief, 3000 PSI Coil, DSL 10V DC Valve, Spool, Three-Way, Two Position Valve, Flow Control Valve, Two-Way N.C Coil, PDL 12V DC, Delta (waterproof, w/ O-rings) Screw, 5/16"-18 x 3-3/4" HHCS Gr8 YZ Washer, 5/16" Split Lock YZ High-Alloy Washer, 3/8"SAE Hardened Washer, 3/8" Split Lock High-Alloy YZ Screw, 3/8"-16 x 1-1/4" HHCS Gr8 YZ O-ring, 3/32" C.S.W., /16" I.D., 3/4" O.D.Neoprene POWER UNIT PARTS 37

38 LIGHTS & CONTROL PARTS 5A A A 3A

39 LIGHTS & CONTROL PARTS REF PART QUANTITY NUMBER DESCRIPTION 1A Harness Assembly, Plow Includes Ref 1,2 & 62046, 6203, 6143, Harness, Plow Weather Cap, Rubber, Plow Side Connector, Electric, Female, Plastic Terminal, Female (18-16AWG) Cable Tie, Black, 15" Nominal Length Heavy Duty - 120psi Min Tensile -.3" Wide Harness, Diode Loop 3A Harness Assembly, Vehicle Includes Ref 3,4 & 6143, 62124, 62212, 62035, 62144, 62056, 62072, 62008, 6200, 62016, Harness, Vehicle Weather Cap, Rubber, Vehicle Side Fuse, 1/4" Dia. x 1-1/4" BUSS ARC 15A, 32V Harness, Main Lighting Weather Cap, Rubber, Lighting Harness Headlight Relay, CB1-D-12V, Power Contactor (Solenoid), 12VDC-225A Ground Wire, Power Contactor, 24" Terminal, End Ring, 3/8" I.D. Copper, 4 Gauge Fuse Clip, Mini Fuse Clip, Auto Blade Connector, Splice Lock (18-14 WAG) Screw, x 3/4"Hex Washer Self-Drilling 5A Headlight Assembly, Plow Includes Ref 5-10 & Headlight, Driver s Side Headlight, Passenger s Side Harness (with 6-pin plug), Plow Headlight Side Lighting Harness Repair Kit, Harness Side Bulb, Sealed Beam Halogen (H6545/H4666) Corrosion Preventive Compound (2fl.oz.) Adapter, Headlight Ball Stud Mount Washer, 1/2" I.D. x 1"O.D. Neoprene Backing Galvanized Washer, 7/16" Ext. Tooth Lock YZ Nut, 7/16"-14 Hex Gr8 YZ Cap, 2-1/4" I.D., 2-3/8" O.D. x 3/4", Black Vinyl Light Tower Light Tower 13A Rocker Switch/Joystick Control Station Assembly Includes Ref 13-23, 61036, 62183, Housing, Control Station Switch, Rocker, SPST, Off-None-On, 15A, 250V AC Housing Plate, Control Station Strap, 61" Velcro with 2" Metal D-Ring Black Connector, Electrical - 12-pin & 2-pin Plugs Joystick, Four-Way, Subminiature, No Switches Switch, Rocker, SPDT, On-Off-On, 10A, 250V AC - Sys. Power On/Off - Hitch On Label, Plow Lights/Power Switch ON/OFF (Blz1053) Switch, Rocker, DPDT, (On)-Off-(On), White 10A, 250VAC-Wing Extend & Retract Screw, x 1/2" Pan Head Machine Z Label, Control Station (Blz1028) U-Clip, Circuit Board with Switches Timed Delay, 0.5 Sec.SSAC MSM 10.5W Decal, 2-1/4" x -3/4" Undercarriage Push Beam, (Blz1071) Decal, 1-1/2" x 6-1/2" Undercarriage Push Beam, (Blz1072) 3

40 ACCESSORIES & KITS 1. Help channel air flow to your truck radiator during the long haul over the road. Mounted front and center, our custom airfoil redirects air over the top of the blade and into the grill of your vehicle. The airfoil is shipped with complete mounting hardware. 2. Rugged and durable, the 3/8"thick, 2-ply construction keeps snow off of your windshield and in its place on the ground! The one piece rubber design allows for wing clearance and provides optimum snow deflection. The deflector is shipped with a Blizzard Power Plow vinyl decal and complete mounting hardware. 3. This kit includes the most common replacement parts: Angle cylinder hose, lift cylinder hose, hitch pin w/hair pin cotter, angle cylinder clevis pin w/cotter, 0 angle cylinder fitting, solenoid, Power Hitch toggle switch, corrosion preventive compound (2 oz.) and 10A fuse. The compact & durable plastic case (13.5"x"x3.3") allows for easy storage behind or under your seat. 4. Beef-up your Power Plow snowplow with our 3/8" thick wing cutting edges. These edges are built to withstand heavy plow use on the roughest road surfaces and also provide added material for protection against sidewalk curb wear. Mounting hardware included. 5. Blizzard hydraulic oil is specially formulated for use in Blizzard snowplows and can significantly enhance the operation and performance of the hydraulic system. Blizzard zinc-free hydraulic oil maintains its viscosity to temperatures as low as - 60 F.Blizzard oil is available by the quart, gallon, case or drum. 6. Our easy-to-install, adjustable pedestal mount will position either Power Plow snowplow control station how you want it! Ideal for bucket seat vehicles with low center consoles. Pedestal accessory shipped with complete hardware and adapter plate. 7. The Power Plow snowplow touch pad control offers ergonomic comfort behind the wheel. Whether you hold it in your hand, strap it on your leg, wrap it around your seat or mount it to the dashboard, this control will provide the flexibility you need! Control is shipped with a molded plastic leg tray, adjustable Velcro strap and extra Velcro patches. Measures 3-1/4" x 3-1/4" x 1-5/16" Get the response you demand from your plow with this easy-to install add-on and experience increased power and speed to all of the plow hydraulic functions! The auxiliary manifold bolts right up to the existing manifold and pump bracket without any modifications needed. Manifold provides up to 30 gpm input (4000 psi max.) from the vehicle pump and 2-3 gpm output (2500 psi max.) to the existing hydraulic manifold. Hydraulic hoses, fittings and pump not included.. Durable and long lasting, the Power Plow polyurethane mold-board and wing cutting edges will keep you plowing longer and safer! Specially formulated for snowplowing applications, Blizzard polyedges resist gouging, provide superior wear life and effectively reduce plowing noise. Ideal for all plowing conditions. Edges are shipped with mounting hardware.